Onwa KAP-866 User Manual

KAP-866

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OPERATOR`S MANUAL

Autopilot

R

KAP-866

CONTENTS

WARNING 1

FEATURES 2

1 OPERATION 3

1.1 Controls 3

1.2 Turning the power on/off 3

1.3 Display backlight and contrast adjustment 4

1.4 Standby Mode 4

1.5 Auto Mode 5

1.5.1 Weather Control 5

1.5.2 Rudder Control (Rudder Ratio) 5

1.5.3 Counter-Rudder Control 6

1.6 Follow-Up Mode 6

1.7 Navigation Mode 7

2 MU ST S 10EN ET ING

2.1 10Function Menu

2.1.1 10Set Rudder Limit

2.1.2 11Set Trim

2.1.3 11Stopwatch Timer Alarm

2.1.4 11Off Course Alarm

2.2 13Installation Menu

2.2.1 Select Remote Unit 13

2.2.2 Select Rudder Feedback unit 13

2.2.3 Select Magnetic Sensor Unit 14

2.2.4 Trim Setting 14

2.2.5 Auto Heading Adjust 15

2.2.6 Manual Heading Setting 16

2.2.7 Heading Alignment Setting 17

2.2.8 Language Setting 17

2.2.9 Output Setting 18

2.2.10 Factory Default Setting 18

2.2.11 Select Type of Steerin g System 19

CONTENTS

3 AUTOPILOT INSTALLATION 20

3.1 Installation of Main Unit 20

3.1.1 Position 20

3.1.2 Wiring 20

3.1.3 Magnetic Effect 20

3.1.4 Power supply consideration 20

3.2 Installation of Rudder Feedback 21

3.2.1 Position 21

3.2.2 22Wiring

3.3 Installation of Compass 23

3.3.1 Installing a Compass-Top Sensor (KCS-20) 23

3.3.2 24Installing an indoor magnetic sensor unit (KFG-25)

3.3.3 26Installation an outdoor magnetic sensor unit (KFG-28)

3.4 Installation of solenoil 27

3.5 Installation of reversing motor pump 28

3.6 NMEA Connection 28

3.7 External Alarm Installation 29

3.8 Installation of Remote Units 30

3.9 Installation of external rudder indicator 31

4 Commissioning Checks Connection Tests 32

5 MAIN NANCE, TROUBLESHOOTING 33TE

5.1 Preventive maintenance 33

5.2 Troubleshooting 34

6 TECHNICAL PARAMETERS 35

6.1 General 35

6.2 Output /Input (IEC61162) 35

6.3 Environmental Conditions 35

6.4 Display 35

6.5 Electrical parameters: 35

7 INTERCONNECTION DIAGRAM 36

8 DISPLAY UNIT SIZE 38

SAFETY INSTRUCTIONS

Safety Instructions for the Operator

WARNING

Do not open the equipment.

Only qualified personnel should work
inside the equipment.

Do not disassemble or modify the
equipment.

Fire,electrical shock or serious injury
can result.

Immediately turn off the power at
the switchboard if the equipment is
emitting smoke or fire.

Continued use of the equipment can
cause fire or electrical shock.Contact
a ONWA agent for service.

Use the proper fuse.

Use of a wrong fuse can damage the
equipment or cause fire.

Be sure the power supply is
compatible with the equipment.

Incorrect power supply may cause the
equipment to overheat.

The useable temperature range

-15 to 55 for the display unit.

Use of the equipment out of those
ranges may damage the equipment.

Safety Instructions for the Installer

WARNING

Do not open the cover unless totally
familiar with electrical circuits and
service manual.

Improper handling can result in
electrical shock.

Turn off the power at the switchboard
before beginning the installation.

Fire or electrical shock can result if the
power is left on.

Be sure that the power supply is
compatible with the voltage rating
of the equipment.

Connection of an incorrect power
supply can cause fire or equipment
damage.

Use the proper fuse.

Use of a wrong fuse can damage the
equipment or cause fire.

NOTICE

Observe the following compass safe
distances to prevent interference to
a magnetic compass:

Display unit

Processor

Standard
Compass

0.4 m 0.3 m

1.2 m

Steering
Compass

1.2 m

WARNING!

Automatic pilots are designed to be a navigational aid. As an automatic steering

aid, an autopilot can alleviate the boredom of hand steering.

This allows the operator of the vessel time to attend to other duties, keep a more

accurate check of navigation duties or just relax and enjoy the trip.

HOWEVER, THE AUTOPILOT SHOULD NOT BE LEFT SOLELY IN

CHARGE OF THE VESSEL AND AN ADEQUATE WATCH SHOULD BE

MAINTAINED AT ALL TIMES.

IT IS NOT RECOMMENDED THAT THE AUTOPILOT BE USED WHILE

NAVIGATING IN RESTRICTED WATERWAYS AS WATER CURRENTS,

WIND CHANGES OR RADIO TRANSMITTER INTERFERENCE MAY

AFFCT VESSEL COURSE SUFFICIENTLY TO ENDANGER YOUR OWN

OR OTHER VESSELS.

1

FOREWORD

Thanks you for purchasing the ONWA KAP-866 Autopilot.

The KAP-866 Autopilot controls the vessel steering through mechanical drive,

reversing pump set, solenoid valves or relays.

The compass must be installed in a place free of magnetic interference, and

connected to the autopilot via the cable supplied.

The rudder feedback must be attached to the rudder in such a way that it can

accurately measure the position of the ship's rudder. This must also be conne-

cted to the autopilot via the cable supplied.

KAP-866 is designed and constructed to meet the rigorous demands of the

marine environment. However, no machine can perform its intended function

unless properly installed and maintained.

Please carefully read and follow the operation, installation and maintenance

procedures set forth in this manual.

We would appreciate feedback from you.

Thank you for considering and purchasing ONWA.

2

1.1 Controls

Ship's heading field

1. OPERATION1. OPERATION

MENU:
Press once: Open Activate menu
Press 5 sec: Activate installation menu

Control field

CTRL:
Select controls setting.

Mode field

Rudder angle
field

RR

40 50 60 70 80 E 100 110 120

Heading

080

Weather

16

Set Course

10

Rudder
Counter

4

060

A

Mode

20

ST-BY AUTO F-UP NAV

Mode Selection

MENU

ESC

KAP-866

POWER

CTRL

KNOB/ENT:
Choose menu item.
Change course heading.
Press the [Enter]

ARROW KEYS:
Press once to change one
degree course-to-steer

POWER:
To switch on/off the unit.
To adjust display backlight
and contrast

ESC:
Exit menu and operation.

1.2 Turning the power on/off

Power on

Press [POWER] once to switch on the unit with a "beep" sound.

KAP-866 Autopilot

Ver : 20120101001

3

R

TURNING OFF

IN 3 SEC

NOTE: If the device is a long time when not in use,Better to turn off the
main switch of the power supply unit.

1.3 Display backlight and contrast adjustment

1. Press the [POWER] key. Dialog box for adjustment of Panel brilliance and

display contrast.

40 50 60 70 80 E 100 110 120

Heading

080

Weather
Rudder
Counter

Mode

20

2. Turn the Knob to select BRILL box and press the Knob to confirm, then

turning the Knob to change the backlight brilliance and press the Knob

again to confirm the setting.

3. Turn the Knob to select CONTRAST box and press the Knob to confirm,

then turning the Knob to change the display contrast and press the Knob

again to confirm the setting.

4. Press [ESC] to exit.

16

10

4

A

8

Set Course

42

060

1.4 Standby Mode

When switching on the unit it stays on

Standby Mode and "Man" display on the

Mode field to indicate the steering oper-

ate manually.

In any steering mode, press [ST-BY] can

return to manual steering mode.

4

40 50 60 70 80 E 100 110 120

Heading

Weather
Rudder
Counter

Mode

3

Mode field

Rudder Angle Field

080

3

10

4

Man

Heading

080

Command field

1.5 Auto Mode

Press [Auto] change steering mode to Auto

and "A" display on the Mode field to indicate

the steering operate automatic to the set course.

The autopilot will lock on to the current

heading. Change course as follows :

a) Rotating the Knob to change the course-to-steer by one

degree for each "click".

b) Pressing the [ ] or [ ] arrow keys will also cause a one degree course

change for each press to corresponding direction.

Controls:

press the [CTRL] to select corresponding controls, Weather, Rudder and Counter

Rudder. Turning the Knob to change the setting of the controls then press the

Knob to confirm the setting or press [ESC] to exit.

40 50 60 70 80 E 100 110 120

Heading

080

Weather
Rudder
Counter

Mode

20

16

10

4

A

Set Course

060

1.5.1 Weather Control

This setting is used for adjusting the autopilot's reponse on varies sea conditions.

The weather value sets the desired accuracy of the vesse l steering. A high

weather setting will cause the vessel to steer very accurately but may cause

excessive use of the steering.

In good weather, set this control to a high value, but ensure that the drive arrows

display on ship's heading field would not flickering continuously. This will give

the straightest possible course.

In poor weather, reduce this setting to prevent over-working the steering.

1.5.2 Rudder Control (Rudder Ratio)

This setting is used to determine the amount of rudder that the vessel requires

for steering (actually, the amount of rudder angle applied for a given angle

off course).

The centre position is usually suitable for most vessels, but also should depends

on the vessel's steering be sensitive or slow, adjustment maybe required.

In general, an agile vessel with a relatively large rudder or very small keel will

require a small rudder setting. A large, slow vessel may require a high value

for the rudder ratio.

5

This may also be adjusted according to speed, low speeds may require more

rudder angle for steering than high speeds.

A value of 1 signifies the minimum amount of applied rudder (for sensitive

steering, large rudders or low gearing ratio.

A value of 20 signifies the minimum amount of applied rudder (for vessels

with slow steering, small rudders or high gear ratio).

When the rudder setting is too low, turns will take an excessive amount of time

and the vessel may wander .

When the rudder setting is too high, turns will be rapid and the vessel will

oversteer.

1.5.3 Counter-Rudder Control

In some vessels, changing course requires a large amount of rudder to be

applied Initially, and then a smaller amount of rudder in the REVERSE direc-

tion to stop the vessel from swinging beyond its desired course. This is called

counter-rudder.

The KAP-866 Autopilot has this feature built-in. A counter-rudder setting of "1"

gives no counter-rudder steering, suitable for light and manouverable vessels.

If you find your ship over-steering when under autopilot control, increase the

counter-rudder setting by a couple of steps, and see if the next course change

behaves better.

Once the correct setting is found for your vessel, it should not need to be

changed. Unless the loading of your vessel is changed.

If you adjust the counter-rudder seting to "A" the counter-rudder functioning

automatically apply depends on the rate of vessel turning to the set course.

1.6 Follow-Up Mode

Press [FU] to change the steering mode to Follow Up and "FU" display on

the Mode field to indicate the rudder steer follows the set command angle

on the Command field.

6

Set rudder angle can change the course of the

autopilot :

a) Rotating the knob will change the rudder

angle command by one degree for each "click".

Rudder will steer and stop on the set angle and

direction.

40 50 60

Heading

Weather
Rudder
Counter

Mode

20

70 80 E 100 110 120

080

16
10

FU

4

P20

Set Rudder

Rotate the Knob to clockwise direction to drive the rudder to Starboard side while

rotate the Knob to Counter-Clockwise direction to drive the rudder to Port side.

b) Pressing the arrow keys will cause a one rudder angle change

[ ] or [ ]

in that direction.

1.7 Navigation Mode

For use when KAP-866 is interfaced to a GPS

Navigator with NMEA0183 data output.

In Navigation mode this allows the autopilot to

be directed by the GPS Navigator, enabling

automatic heading changes and eliminating the

effects of wind and tide.

The number displays on the Command field

indicates the course-to-steer,which will be the

bearing between the origin ad destination Waypoints,plus a factor to correct for

the Current crosstrack-error(XTE).

Engaging Navigation Mode

Press [ NAV] change the steering mode to Navigation mode and "NAV" display

on the Mode field to indicate the steering is directed by the connected GPS

Navigator.

The vessel will begin turnin from its current course to the course requested by

the GPS Navigation.

40 50 60 70 80 E 100 110 120

Heading

080

Weather
Rudder
Counter

Mode

20

16

10

4

Nav

BRG

060

If no GPS data is being received by the KAP-866, the autopilot will lock onto

the course of the vessel at the time that Navigation Mode was engaged, and the

No GPS Data alarm shall sound.

7

Setting up your GPS Navigator

Because there are a great variety of GPS Navigator that will work with this

autopilot, the following is a guide only. For more information, Please study

your GPS Navigator manual.

The GPS Navigator must be set up to output NMEA0183 data on a pair of

wires which are connected to the "GPS IN" terminal connections on KAP-866.

The data generated must include at least one of the followings:

The APA sentence.

The APB sentence.

The BOD and XTE Sentences.

If only the XTE data sentence is available, the pilot can steer in a Restricted

manner. See later in this section.

The GPS unit must then be commanded to go to a waypoint, or to follow a line

joining two or more waypoints (called a route).

This unit will then send information to the autopilot from which can be calcu-

lated the course-to-steer. IF several waypoints are linked together into a single

route, and the GPS unit is set to "auto-sequenence" between them, and an

"arrival zone" of more than 0.1 NM(Nautical Miles)is set so that the GPS can

detect when the vessel has reached a waypoint, then the KAP-866 will be able

to steer from each waypoint to the next without intervention.

If only the XTE information is available from your GPS unit then your vessel

must be on track, and heading in the correct direction before engaging the GPS

mode, and the auto-sequencing feature is not available.

8

Remember:

Prior to engaging Navigator mode, a route must be programmed into the GPS

for the Autopilot to follow.

No GPS Data Alarm

If the autopilot is not receiving valid information while in GPS Mode, the No

GPS Data alarm will sound, and "NO GPS" will blink on the display. This

counld be caused by:

Incorrect wiring of the GPS to the KAP-866.

Incorrect data output from the GPS unit.

No route set up or selected in the GPS unit.

No location fix at the GPS unit.

The bearings generated by the GPS unit must correspond to the bearings the

KAP-866 is receiving from its magnetic compass. The greater the difference

between these Bearings, the less accurate will be the Navigator mode steering.

Ensure that the GPS unit has the correct magnetic correction factor.

Ensure that the KAP-866 compass is correctly aligned and installed.

9

2. MENU SETTINGS2. MENU SETTINGS

2.1 Function Menu

Press [MENU] to display the Function menu.

Turning the Knob to move cursor between the Function menu items. Press the

Knob to confirm the selection. Turn the Knob to change the setting in the

setting in the selected item. Press the Knob to confirm the setting or press

[ESC] to exit.

SET RUDDER LIMIT : 22

SET TRIM : +00

OFF COURSE ALARM : 00

STOPWATCH TIMER ALARM : 00

FUNCTION MENU

2.1.1 Set Rudder Limit

There are physical limitations to the angle that the rudder can move through.

If the autopilot attempts to drive the rudder past these limits, damage to

the steering gear may occur.

Setting Rudder Limit is to prevent the rudder from over-steer beyond the set

limit. The Rudder Limit will function before the steering system reach the

mechanic limit.

There are 2 symbols "P_L" (Port Limit) and "S_L" (Starboard limit) will

appear on the display. When you see either of these 2 symbols:

a) When rudder moves excess the set Port Limit (or Starboard Limit) a "P_L"

(or S_L) will appear on the display. No port (or Starboard) rudder movement

command will be sent out from the autopilot.

b) The functioning of Starboard Limit (S_L) us same as Port Limit (P_L)

Note: The factory default setting of Rudder limit is 30 degrees. That means if

rudder feedback unit is properly installed then when the rudder is moved over

Port or Starboard 30 degrees, the display will show P_L or S_L.

10

2.1.2 Set Trim

There are circumstances in which the autopilot may set the rudder in the centre

(according to its feedback unit)But the vessel does not steer straight ahead.

Reasons for this are:

1. The rudder may not be perfectly aligned.

2. There may be a side-wind, current, net drag, etc, which causes the vessel to

steer to one side.

KAP-866 can compensate for these errors, but may take a few minutes to core

completely. Adjusting the "SET TRIM" can eliminate these Errors immediately.

To find the correct trim setting:

With the vessel Travelling ahead, switch the autopilot to "Standby" mode.

Adjust the trim control until the ship steers straight.

The SET TRIM is not intended to be used for adjusting the vessel course in

"Auto" or "F-UP" steer mode.

2.1.3 Stopwatch Timer Alarm

In any mode press [MENU] to display Function menu. Rotate the Knob to

move cursor to "STOPWATCH TIMER ALARM" and press the Knob to confirm.

Rotate the Knob to change the setting between 0~180 minutes and press Knob

to confirm and save setting.

After setting "STOPWATCH TIMER ALARM" the countdown will start once

"AUTO" or "NAV" mode is set. when countdown to "0" from preset time the

"STOPWATCH TIMER ALARM" will be triggered, a continuously short "beep"

sound and flashing "STOPWATCH TIMER ALARM!" will appear on the display.

40 50 60 70 80 E 100 110 120

STOPWATCH TIMER ALARM!

Heading

080

Weather
Rudder
Counter

Mode

20

16

10

4

A

11

Set Course

060

The user can press [ESC] to cancel the alarm and the timer will start another

countdown again. Once countdown to "0" from the preset time the "STOPWA-

TCH TIMER ALARM" will be triggered again. The "STOPWATCH TIMER

ALARM" will be carried out repeatedly until either the user select other modes

(ST-BY or F-UP) than "AUTO" or "NAV" modes or change the timer to "000".

If the "STOPWATCH TIMER ALARM" is triggered and the user without press

[ESC] to cancel the alarm within one minute, the alarm sound will change

form short "beep" to continuous long "beep" and the external alarm (if installed)

will be triggered.

2.1.4 Off Course Alarm

An alarm will sound if the vessel has deviated from its desired course by more

than a set number of degrees. This can be caused by a number of steering faults,

any of which require attention by the crew.

The angle at which this alarm sounds may be set to any value between 1 and

180 degrees.

To set the off-course alarm angle

In any mode press [MENU] to display Function menu. Rotate the Knob to move

cursor to "Off Course Alarm" and press the Knob to confirm. Rotate the Konb

to change setting from 0~180 degrees and press the Knob to save setting or

press [ESC] to exit without save the setting.

When the allowable angle is exceeded, the off-course alarm will sound and a

flashing "OFF COURSE" will show on display. When the vessel is brought on

to its correct course again, the alarm will cease.

Note that the alarm will sound if a large course change is entered. This alarm

will cease as soon as the vessel completes its course change. The alarm may

also sound when changing from one section of a GPS route to another, and will

cancel itself when the course change is completed.

The default value for the off-course angle (ie the one set when the KAP-866 is

turned on) is 30 degrees.

12

2.2 Installation Menu

Press and hold [MENU] button to enter the Installation menu. Rotate the Konb

to the desire item and press the knob to enter the that item to make the

related change.

INSTALLATION MENU

SELECT REMOTE UNIT

SELECT RUDDER FEEDBACK UNIT
SELECT MAGNETIC SENSOR UNIT
TRIM SETTING
AUTO HEADING ADJUST

MANUAL HEADING SETTING

HEADING ALIGNMENT SETTING
LANGUAGE SETTING

2.2.1 Select Remote Unit

There are 2 kinds of option remote units are available from Onwa, Hand Remote

(RT580) and Electric Wheel(RW230).Choose either remote unit which is installed.

Note: No remote set up is needed if no remite units is installed.

INSTALLATION MENU

SELECT REMOTE UNIT

SELECT REMOTE UNIT

SELECT RUDDER FEEDBACK UNIT
SELECT MAGNETIC SENSOR UNIT

1. HAND REMOTCH

TRIM SETTING

2. ELECTRIC WHEEL

AUTO HEADING ADJUST

Cancel [ES C] ok [EN T]

MANUAL HEADING SETTING

HEADING ALIGNMENT SETTING
LANGUAGE SETTING

2.2.2 Select Rudder Feedback unit

There are 2 kinds of Rudder Feedback units are available from Onwa. heavy

duty (KRF35) and light duty (KRF36) rudder feedback unit. Choose the correct

rudder feedback unit which is installed. Usually light duty rudder feedback

unit is for vessel below length of 50 meters (165 feet)

Note: Choice of Rudder Feedback Unit:

1) Heavy Duty Rudder Feedback Unit KRF35-RFUH

2) Light Duty Rudder Feedback Unit KRF-36-RFUS

INSTALLATION MENU

SELECT REMOTE UNIT

SELECT RUDDER FEEDBACK UNIT

SELECT MAGNETIC SENSOR UNIT
TRIM SETTING
AUTO HEADING ADJUST

MANUAL HEADING SETTING

HEADING ALIGNMENT SETTING
LANGUAGE SETTING

13

INSTALLATION MENU

SELECT REMOTE UNIT

SELECT RUDDER FEEDBACK UNIT

SELECT RUDDER FEEDBACK UNIT

SELECT MAGNETIC SENSOR UNIT

1. RFUH

TRIM SETTING

2. RFUS

AUTO HEADING ADJUST

Cancel [ES C] ok [EN T]

MANUAL HEADING SETTING

HEADING ALIGNMENT SETTING
LANGUAGE SETTING

2.2.3 Select Magnetic Sensor Unit

There are 2 kinds of Magnetic Heading Sensor units are available from Onwa,

Fluxgate compass Top Sensor.

Note: Choice of Magnetic Sensor Unit

1) Fluxgate Sensor KFG25 and KFG28-FLUXGATE SENSOR

2) Compass Top Sensor KCS20-COMPASS TOP SENSOR

INSTALLATION MENU

SELECT REMOTE UNIT

SELECT MAGNETIC SENSOR UNIT

SELECT RUDDER FEEDBACK UNIT

SELECT MAGNETIC SENSOR UNIT

1. FLUXGATE SENSOR

TRIM SETTING

2. COMPASS TOP SENSOR

AUTO HEADING ADJUST

Cancel [ES C] ok [EN T]

MANUAL HEADING SETTING

HEADING ALIGNMENT SETTING
LANGUAGE SETTING

2.2.4 Trim Setting

Sometimes for some reasons the installation of Rudder Feedback Unit is not

100% aligned with the position of the Rudder. We could use the Trim Setting

to compensate the installation error.

Note: It is not advised to use this function to compensate the error if the angle

different is excess 5 degrees between actual rudder angle and display angle

from rudder feedback unit. Re-installation should be carried out if the said

angle error is excessed 5 degrees

INSTALLATION MENU

SELECT REMOTE UNIT

SELECT RUDDER FEEDBACK UNIT
SELECT MAGNETIC SENSOR UNIT

TRIM SETTING

AUTO HEADING ADJUST

MANUAL HEADING SETTING

HEADING ALIGNMENT SETTING
LANGUAGE SETTING

TRIM SETTING

+00

Cancel [ ESC] ok [E NT]

14

2.2.5 Auto Heading Adjust

The compass has been calibrated during manufacture. This calibration will be

satisfactory for almost all installations. If you have a steel vessel, or some

other factor which causes the compass to perform poorly, the calibration

procedure will adjust compass characteristics to compensate.

The calibration should only be done if the compass is known to be inaccurate.

If the KAP-866 display as constant offset (e.g. The compass reads 3 degrees

high on all bearings), simply rotate the Fluxgate Sensor case to align bearings

with the ships compass. It is not necessary to re-calibrate the compass as desc-

ribed below.

If the KAP-866 has inconsistent variation on different headings, the following

calibration procedure can be carried out. This procedure should only be done

in calm waters with adequate sea room.

In the menu select"AUTO HEADING ADJUST"and press knob The following

window appears:

INSTALLATION MENU

SELECT REMOTE UNIT

AUTO HEADING ADJUST

SELECT RUDDER FEEDBACK UNIT
SELECT MAGNETIC SENSOR UNIT

Auto heading adjusting !

Pleases keep constant speed less

TRIM SETTING

than 2 minutes for each turn

AUTO HEADING ADJUST

Cancel [ES C] ok [EN T]

MANUAL HEADING SETTING

HEADING ALIGNMENT SETTING
LANGUAGE SETTING

Press the knob to start auto heading adjustment "Auto heading adjusting"

message will appear on the lower part of the display and heading update per

second to show the status of adjustment.

40 50 60 70 80 E 100 110 120

080

Weather
Rudder
Counter

Mode

Auto heading adjusting...

Set Course

060

15

Steer the vessel in clockwise direction with constant speed less than 2 minutes

per each circle until the following correction success message appear.

40 50 60 70 80 E 100 110 120

40 50 60 70 80 E 100 110 120

080

Weather
Rudder
Counter

Mode

Auto heading adjusting success!

Set Course

060

Weather
Rudder
Counter

Mode

Auto heading adjustment failed!

080

Set Course

060

The message goes away after 6 seconds.

In case of correction fails repeat the above steps until the correction is successful.

2.2.6 Manual Heading Setting

Manual Compensation is a supplement to the type of single orientation parabola

to adjacent 10 degrees. This method could be done by qualified personnel.

1) In the Installation menu select "MANUAL HEADING SETTING" and press

the Knob, the following window appears:

MANUAL HEADING ADJUST

+00

+00
+00
+00

120
150
180
210

0

30
60
90

Cancel [ESC] OK [ENT]

+00
+00
+00
+00

240
270
300
330

+00
+00
+00
+00

2) Rotate the Knob to choose which bearing you want to correct and press the

Knob to confirm. Rotate the Knob to apply compensation and press the Knob

to save the change or press [ESC] to exit without save.

Note: Anyway ship's magnetic compass and heading on KAP-866 shows each

azimuth are unlikely to maintain consistent.

16

2.2.7 Heading Alignment Setting

Adjustment of heading might be needed during installation. Usually a fixed

error in all direction would exist. It is due to the mechanical error when

fixing.

1) Rotate the Knob to select "HEADING ALIGNMENT SETTING" in the inst-

allation menu. Press the Knob to show the following window:

INSTALLATION MENU

SELECT REMOTE UNIT

SELECT RUDDER FEEDBACK UNIT

Heading alignment setting

SELECT MAGNETIC SENSOR UNIT
TRIM SETTING
AUTO HEADING ADJUST

MANUAL HEADING SETTING

HEADING ALIGNMENT SETTING

LANGUAGE SETTING

134 + 00 134

Cancel [ ESC] ok [E NT]

2) Rotate the Knob to change the heading alignment setting and press the Knob

to save the change or press [ESC] to exist the window with out save the

change.

2.2.8 Language Setting

Choose different languages for different users.

1) Rotate the Knob to select "LANGUAGE SETTING" in the installation menu.

Press the Knob to show the following window:

INSTALLATION MENU

SELECT REMOTE UNIT

SELECT RUDDER FEEDBACK UNIT

LANGUAGE SETTING

SELECT MAGNETIC SENSOR UNIT
TRIM SETTING
AUTO HEADING ADJUST

Cancel [ ESC] ok [E NT]

MANUAL HEADING SETTING

HEADING ALIGNMENT SETTING

LANGUAGE SETTING

ENGLISH

2) Rotate the Knob to select desire language and press the Knob to save change

or press [ESC] to exit without save the change.

17

2.2.9 Output Setting

INSTALLATION MENU

OUTPUT SETTING

FACTORY DERAULT SETTING

OUTPUT SETTING

SELECT TYPE OFSTEERING SYSTEM

1. HDT

2. HDM

3. HDG

Cancel [ ESC] ok [E NT]

Output data available from KAP-866 includes the following three types:

HDT: True heading

HDM: Magnetic heading

HDG: Magnetic heading & magnetic variation value*

Note*: the default magnetic value is 0 since there are no enough data to

calculate the magnetic variation. In calculation of magnetic value it requires

position data (LON/LAT) and date, those data are not available in KAP-866.

Note:

Since there are no available data in KAP-866 for calculation of magnetic vari-

ation therefore:

- "HDT" outputs magnetic bearing instead of ture heading data.

- The magnetic variation data in "HDM" would be "0"

2.2.10 Factory Default Setting

For any reason need to reset all settings to factory default setting you can do

as following instruction.

1. Rotate the knob to select "FACTORY DEFAULT SETTING" in installation

menu. Press the Knob to show there following window:

INSTALLATION MENU

OUTPUT SETTING

FACTORY DERAULT SETTING

FACTORY DEFAULT

SELECT TYPE OFSTEERING SYSTEM

R estore to
factory default setting !

Cancel [ ESC] ok [E NT]

2. Press the Knob to clear all saved settings or press [ESC] to exist without

clear the saved setting.

Note: When you select to load factory default setting all saved settings would

be cleared. This action can not reversible.

18

2.2.11 Select Type of Steering System

Some vessel the steering system is either common positive solenoid or common

negative solenoid or reversing motor. KAP-866 can be set to work with above

systems.

1. Rotate the Knob to select "SELECT TYPE OF STEERING SYSTEM" in the

installation menu. Press the Knob to show the following selection:

INSTALLATION MENU

OUTPUT SETTING

SELECT TYPE OF STEERING SYSTEM

FACTORY DERAULT SETTING

SELECT TYPE OFSTEERING SYSTEM

1. COMMON POSITIVE SOLENOID

2. COMMON NEGATIVE SOLENOID

3. REVERSING MOTOR

Cancel [ES C] ok [EN T]

2. Rotate the Knob to select the correct system and press the Knob to save

setting or press [ESC] to exit without save the change.

19

3. AUTOPILOT INSTALLATION3. AUTOPILOT INSTALLATION

3.1 Installation of Main Unit

3.1.1 Position

The KAP-866 main panel should be mounted in an accessible position, Protec-

ted from rain or salt water.

3.1.2 Wiring

Cablings have to be run from KAP-866 to the rudder feedback unit, compass

unit, compass unit and steering drive system. Wiring should be kept as far away

as possible from radio aerials and aerial cables to prevent interference to the

radio, and to prevent transmitted signals from the radio influencing to the

autopilot. The power source for the autopilot should be fused separately from

other equipment. Maintain conventional colour coding and, if necessary, mark

the cables for ease of identification.

Connection - As per diagram labelled Connection Diagram for KAP-866.

3.1.3 Magnetic Effect

As a minimum amount of steel is used in the control unit. there is negligible

effect on a steering compass. Some radio interference may be caused and the

routing of cables should be considered when wiring the vessel.

3.1.4 Power supply consideration

KAP-866 can be operated with 12VDC or 24VDC. To consider to use 12VDC

or 24VDC you have to find out the operating voltage of steering drive system

onboard first. Usually the steering drive system is solenoid drive or reversing

motor drive. If the steering drive system onboard is operated on 12VDC the

you have to connect 12VDC power suppl to KAP-866. If the steering drive

system onboard is operated on 24VDC then you have to connect 24VDC power

supply to KAP-866.

AUTOPILOT

MOTOR

RUDDER

COMPASS

REMOTE

ALA/RUDM

NMEA I/O

POWER IN

12VDC or 24VDC

+

-

POWER SUPPLY

20

3.2 Installation of Rudder Feedback

3.2.1 Position

Install rudder feedback as shown in the diagram labelled Rudder Feedback Unit

Installation The unit should be adjacent to the tiller and must copy the angular

movement of the tiller. The markings on the rudder feedback unit indicates the

required movement of the tiller for course correction. It should be installed

with the shaft uppermost, mounted and linked in such a way that the four pivot

points (tiller post, feedback shaft and the adjustable linkage points) form the

four corners of a parallelogram.

The rudder feedback unit is water resistant. However, if it is to be mounted in

a wet position, some effort is necessary to ensure the unit does not become

immersed in water. If necessary the rudder feedback unit may be mounted ups-

ide down, in which case the black and red connections to the KAP-866

ter-minal should be reversed.

Optional

Connection Arm

X

YY

X

Rudder feedback unit

Rudder

21

3.2.2 Wiring

Connect the cable of rudder feedback unit to the 3 pins socket on the rear panel

of KAP-866. To check the wirng of the rudder feedback unit by steer the rudder

to either side (Port or Starboard), see whether the rudder angle indication on

KAP-866 goes to corresponding direction. If the rudder angle indication on

KAP-866 goes to reverse direction against the applied rudder then you need to

reverse the wiring of RED and BLACK.

AUTOPILOT

MOTOR

RUDDER

COMPASS

REMOTE

ALA/RUDM

NMEA I/O

POWER IN

Terminal 5V : + 5 volts Red

Terminal Rud : Signal Yellow

Terminal GND : GND Black

After installation of the feedback unit is complete and the linkage is fitted,

have the steering of the vessel turned lock to lock and ensure:

a)The direction (port or starboard) indicated on the top of the RFU is correct.

b)No undue mechanical strain is placed on the rudder feedback or linkage.

NOTE: THE AUTOPILOT WILL NOT FUNCTION CORRECTLY IF A
RUDDER FEEDBACK IS NOT FITTED, OR IF THE FEEDBACK IS
FAULTY OR INCORRECTLY ADJUSTED.

NOTE: THE RUDDER FEEDBACK UNIT IS FACTORY ALIGNED. THE
ARM SHOULD NOT BE REMOVED OR LOOSENED UNNECESSARILY.
IF ARM IS LOOSENED OR REMOVED, VOLTAGE ALIGNMENT SHOULD
BE CHECKED BEFORE USING THE AUTOPILOT. THIS MUST BE DONE
BY A COMPETENT TECHNICIAN.

22

3.3 Installation of Compass

There are two types of compass suitable for this autopilot - a magnetic sensor

unit (fluxgate), which is a complete compass, and the compass-top sensor

(CTS), which is used together with a standard magnetic ships compass.

3.3.1 Installing a Compass-Top Sensor (KCS-20)

The sensor unit placed on the glass plate of the ships compass, in the exact

centre of the compas card and secured with an adhesive such as double-sided

tape or silicon sealant. Before fixing the sensor in place, align it carefully so

that the KAP-866 compass displays the same bearing as the ships compass.

The compass top sensor is preferred for steel hull vessels provided a suitably

compensated compass is fitted to the vessel.

Bow

Compass sensor

Keel line

Compass

Bow

Parallel travel

Compass sensor

23

3.3.2 Installing an indoor magnetic sensor unit (KFG-25)

The compass unit should be treated carefully as the internal gimbals can be

broken if dropped. Remove any internal packing before use.

The position of this compass is the most important item in the installation of

the autopilot. Good course holding depends on the compass being free from

magnetic interference.

As this compas s has no moving card, it is not necessary for the compass to be

mounted low in the vessel. This is usually a place of high magnetic interference

and should be avoided. However, a position of severe roll such as the top of a

mast should also be avoided.

The compass need not b e mounted in a weatherproof position. The compass

can be mounted on top of a flat surface, on a bulkhead or from the deck head.

Check other side of bulkhead for materials, which may cause magnetic

interference.

Interference from any iron or steel can cause malfunction of the compass unit.

To prevent this occurring a minimum distance of 1 meter(3 feet) should be kept

from any steel or other ferromagnetic materials. This includes speakers and

radios with internal speakers.

Fasten the compass bracket with non-magnetic screws. The compass must be

mounted in a near vertical position.

Desktop mounting

only suitable for fiberglass or wooden vessel.

To ensure the signal of sailing directions is accuracy, please choose a locat-

ion where vibration and shock are minimal.

Installed in the surface of platform

24

Bulkhead mounting

Only suitable for fiberglass or wooden vessel.

The bulkhead installation can save the space.
The bulkhead cannot contain the steel with magnetic interference material.

Deck head

Bracket

Fluxgate Sensor

Bulkhead

Top Mount

Bracket

Side Mount

Fluxgate Sensor

Examples of bulkhead Mount

25

3.3.3 Installation an outdoor magnetic sensor unit (KFG-28)

Outdoor installation

Keep the length of the cable in mind when selecting a mounting location.

It should be far away from their minimum 1 meters to prevent the influence

for iron and steel or other magnetic materials.

use not magnetic screws for fixed the unit.

Select the vertical way of positions for installation.

Please installed the magnetic sensor unit on the top of wheelhouse.

Don't install it in a room so that the magnetic

distortion can be minimized.

Fluxgate Sensor

Fixed screw

Threaded tubes

(At least one meter length)

fluxgate sensor

Cable to display unit

Rope

Wheelhouse

Mast

Radar antenna

Fluxgate Sensor

26

3.4 Installation of solenoid

3.4.1 Connect common positive solenoids as follow. If the rudder goes to

reverse direction against KAP-866 command then you need to reverse the

connection of Motor 1 & Motor 2.

AUTOPILOT

MOTOR

RUDDER

COMPASS

REMOTE

ALA/RUDM

NMEA I/O

POWER IN

Motor 1

Motor 2

Port solenoid

St'b solenoid

Clutch+3

Hand lever (Option)

Negative lead of
power supply

3.4.2 Connect common negative solenoids as follow. If the rudder goes to

reverse direction against KAP-866 command then you need to reverse the

connection of Motor 1 & Motor 2.

AUTOPILOT

MOTOR

RUDDER

COMPASS

REMOTE

ALA/RUDM

NMEA I/O

POWER IN

Motor 1

Motor 2

Clutch+3

Port solenoid

St'b solenoid

Hand lever (Option)

Positive lead of
power supply

27

3.5 Installation of reversing motor pump

Connect reversing motor pump as follow. If the rudder goes to reverse direction

agains t KAP-866 command you need to reverse the connection of Motor 1 &

Motor 2.

AUTOPILOT

MOTOR

RUDDER

COMPASS

REMOTE

ALA/RUDM

NMEA I/O

POWER IN

Motor 1

Reversing Motor Pump

Motor 2

3.6 NMEA Connection

KAP-866 can accept extermal heading information in format of NMEA0183

(4800 8n1) to replace standard fluxgate magnetic sensor. KAP-866 can accept

either one of the followings NMEA0183 sentence for heading source:

1) HDG

2) HDT

3) HDM

When KAP-866 find either one of above NMEA0183 sentence appear on the

data in terminal then KAP-866 can priority choose the NMEA0183 sentence as

heading source.

KAP-866 can also accept GPS information in format of NMEA0183 (4800 8n1)

as course setting command. When there is a route or waypoint navigation is

engaged in the GPS device, KAP-866 will follow the command from the GPS

device to drive the vessel to the waypoint or route which is set in the GPS

device. KAP-866 can accept either one of the following NMEA0183 sentence

for navigation:

1) APA

2) APB

3) BOD & XTE

28

Data In

For GPS navigation or heading information, Connect the data output and data

output and data return wires of external device to the IN+ and IN- of KAP-866

GPS connector. Onwa KGN100 or KGN200 is supplied as an option to convert

the analog signa l (sychro or stepper) of gyrocompass onboard to NMEA0183

data as heading source to KAP-866.

AUTOPILOT

Digital heading source

MOTOR

RUDDER

COMPASS

REMOTE

ALA/RUDM

NMEA I/O

POWER IN

GPS device

3.7 External Alarm Installation

An external buzzer may be connected to the ALA + and ALA - of KAP-866

Alarm connector

The ALA- output will be 10 volts when the alarm is not sounding (with alarm

connected), and approximately 0 volts when active. We recommends a 12-volt

piezo buzzer with maximum current draw not exceeding 250 milliamps be

connected to this output.

If a larger type siren or alarm unit, which draws in excess of 250 milliamps is

used, this must be connected via a relay. The KAP-866 external alarm circuit

is used to energise the relay coil and power to the siren or alarm unit is conn-

ected via the relay contacts.

.

29

The external alarm output is activated if the stopwatch timer has been sounding

for longer than one minute.

AUTOPILOT

MOTOR

RUDDER

COMPASS

REMOTE

ALA/RUDM

NMEA I/O

POWER IN

External Alarm

3.8 Installation of Remote Units

Onw a Hand remote (RT580) and Electric wheel (RW230) is supplied as an

option. Sometimes the user require to operate autopilot away from KAP-866

then this time a remote unit is needed.

The installation of remote units are very easy, just plug and play.

Connect the remote units to the KAP-866 remote connector with the supplied

cable.

AUTOPILOT

MOTOR

RUDDER

COMPASS

REMOTE

ALA/RUDM

NMEA I/O

POWER IN

30

3.9 Installation of external rudder indicator

Onwa rudder indicator KRI-80 is supplied an option. Connect KRI-80 to

KAP-866 as follow:

Canter

+ +

Range

5K control resistor
for dimmer control.

KAP-866 Autopilot

ALARM

Center and Range Calibration is needed on the KRI-80 after installation. Place

the rudder on midship position, adjust "Center" VR on KRI-80 to get "0"

degree on the meter. Place the rudder to 30 degree on either port or starboard,

adjust "Range" VR on KRI-80 to get "30" degree on the meter.

31

4. Commissioning Checks Connection Tests4. Commissioning Checks Connection Tests

Voltage to be connected is the required DC voltage (12 or 24V).

Important note: The supply voltage must match the operating voltage of solen-

oid or reversing motor.

Ensure polarity of the voltage supply is correct.

All electrical connections are correct.

Tie up or cut the unused wires.

Turn steering wheel fully clockwise and visually check that moving and

mechanical parts do not foul; visually check that RFU has moved in the

correct direction as indicated on the RFU label.

Note: RFU = Rudder Feedback Unit

Dockside Tests

Turn steering (by hand) to centre (midships) position.

Turn on power supply

Determine vessel heading by a sighting on known heading or compass.

Align Autopilot magnetic sensor until display reads correct heading.

Select AUTO mode on control unit.

CAUTION: IF AUTOPILOT DRIVES HARD OVER, IMMEDIATELY TURN

CONTROL UNIT OFF, REVERSE MOTOR WIRES MARKED MOT AND MOT

AT THE MOTOR CONNECTOR OF KAP-866 AUTOPILOT.. REPEAT FROM

STEP 1.

Turn course knob 10 degrees to starboard.

Confirm that rudder moves to starboard.

Turn course knob back to centre, then 10 degrees to port.

Confirm that rudder moves to port.

Press [ST-BY] key to leave auto mode.

NOTE: AT NO TIME SHOULD THE AUTOPILOT DRIVE THE RUDDER

INTO THE MECHANICAL STOPS.

The autopilot is now ready for full operational testing (sea trials). Testing

should Only be carried out in clear waterways until you are familiar with the

operation.

32

5. MAINTENANCE, TROUBLESHOOTING5. MAINTENANCE, TROUBLESHOOTING

5.1 Preventive maintenance

WARNINGWARNING

Only qualified personnel should work inside the
equipment.

Regular maintenance is important for good performance . A maintenance prog-

ram should be established and should include the following points.

Check connectors and ground terminal on the fluxgate sensor unit and dis-

play unit for tightness.

Check ground terminal for rust. Clean or replace as necessary.

Check for water leakage in the interconnection cable between fluxgate unit

and display unit. Clean or replace as necessary.

Remove dust and dirt from the display unit and fluxgate sensor unit with a

dry, soft cloth. For the LCD, wipe it carefully to prevent scratching, using

tissue paper and an LCD cleaner. To remove stubborn dirt, use an LCD

cleaner, wiping slowly with tissue paper so as to dissolve the dirt. Change

paper frequently so the dirt will not scratch the LCD. Do not use chemical

cleaners for cleaning they can remove paint and markings.

Note: do not use contain chemical cleaners clean, it might help to eliminate

paint and equipment will be marked.

ELECTRICAL SHOCK HAZARD
Do not open the equipment.

33

5.2 Troubleshooting

This section provides basic troubleshooting procedures which the user may

follow to restore normal operation.
Troubleshooting

Symptom

Power cable on the
display unit

Cannot turn on

the power

Heading indication
changes randomly
when ship is at
anchor or does
not change when
ship moves.

Rudder not
functioning

No rudder angle
indication

If large heading error occurs or heading indication is frequently interrupted,

contact your dealer for advice.

Power supply failure

Blown fuse

Sensor trouble or
Cable contact is bad.

Low voltage output
from KAP-866 or
steering system problem

RFU problem or RFU

cable contact is bad

Cause Remedy

Firmly connect the power
cable

Check the power supply.

Replace fuse with correct
rating. Have a qualified
technician to check if
fuse blown again after
replacement.

Run the diagnostic test
to determine cause.

1. Check voltage supply to

KAP-866

2. Check the steering system

1. Check RFU

2. Check RFU cable

3. Check RFU and rudder

connection

34

6. TECHNICAL PARAMETERS6. TECHNICAL PARAMETERS

6.1 General

6.1.1 Heading Reference: Fluxgate, Magnetic Compass, NMEA

6.1.2 Heading Sensor: KFG-25 (standard), KFG-28 & KCS-20 (option)

6.1.3 Heading Resolution: 1

6.1.4 Course Detection: 0.1

6.2 Output/Input (IEC61162)

6.2.1 Input: Dual NMEA 0183 inputs

Support: APA, APB, BOD & XTE, HDG, HDT, HGM

Baud Rate: 4800, n, 8, 1

6.2.2 Output: One NMEA0183 output

Support: HDG, HGT, HGM

Baud Rate: 4800, n, 8, 1

6.3 Environmental Conditions

6.3.1 Ambient Temperature: -15 ~70

6.3.2 Waterproofing

Display Unit: IPX5

Fluxgate Sensor Unit: IPX5 for KFG25, IPX7 for KFG25

Rudder Feedback: IPX7

6.4 Display

6.4.1 Sunlight viewable high contrast LCD

6.4.2 LCD size: 95(W) 63(H)mm, 240 160 dots

6.5 Electrical parameters:

6.5.1 Operating Voltage: 10 to 30VDC

6.5.2 Power Consumption: Standby mode 0.4 Amps, Auto mode 1.0 Amps Peak

for control unit only.

6.5.3 Drive Output: 20 Amps max

35

7. INTERCONNECTION DIAGRAM7. INTERCONNECTION DIAGRAM

MAGNETIC SENSOR

EXT ALARM

EXT ANGLE IND

AUTOPILOT

MOTOR

RUDDER

COMPASS

REMOTE

ALA/RUDM

NMEA I/O

POWER IN

S

SOLENOID

P

POWER SUPPLY

RUDDER

NMEA0183

REMOTE

GPS

WHEEL

36

SOLENOID OR REVERSING MOTOR

1. MOT+

2. MOT-

3. CLU+

4. CLU-

MAGNETIC SENSOR

1. Green

2. Red

3. Yellow

4. White

5. Blue

6. Shield

EXT ALARM&ANGLE IND

1. Alarm+

2. Alarm-

3. +5V

4. Rudder Indicator

5. GND

REMOTE

1. Adjust

2. Control1

3. Adjust

4. Control2

5. +5V

6. GND

7. +10V

AUTOPILOT

MOTOR

RUDDER

COMPASS

REMOTE

ALA/RUDM

NMEA I/O

POWER IN

POWER

1. DC input-

2. DC input+

RUDDER

1. +5V

2. Sig

3. GND

NMEA0183 I/O

1. Input 1+

2. Input 1-

3. Output +

4. GND

5. Input 2+

6. Input 2-

7. NC

8. GND

37

8. DISPLAY UNIT SIZE

38